Cutting tool tracking and recognition based on infrared and visual imaging systems using principal component analysis (PCA) and discrete wavelet transform (DWT) combined with neural networks

The implementation of computerised condition monitoring systems for the detection cutting tools’ correct installation and fault diagnosis is of a high importance in modern manufacturing industries. The primary function of a condition monitoring system is to check the existence of the tool before starting any machining process and ensure its health during operation. The aim of this study is to assess the detection of the existence of the tool in the spindle and its health (i.e. normal or broken) using infrared and vision systems as a non-contact methodology. The application of Principal Component Analysis (PCA) and Discrete Wavelet Transform (DWT) combined with neural networks are investigated using both types of data in order to establish an effective and reliable novel software program for tool tracking and health recognition. Infrared and visual cameras are used to locate and track the cutting tool during the machining process using a suitable analysis and image processing algorithms. The capabilities of PCA and Discrete Wavelet Transform (DWT) combined with neural networks are investigated in recognising the tool’s condition by comparing the characteristics of the tool to those of known conditions in the training set. The experimental results have shown high performance when using the infrared data in comparison to visual images for the selected image and signal processing algorithms

Major challenges in prognostics: study on benchmarking prognostic datasets

Even though prognostics has been defined to be one of the most difficult tasks in Condition Based Maintenance (CBM), many studies have reported promising results in recent years. The nature of the prognostics problem is different from diagnostics with its own challenges. There exist two major approaches to prognostics: data-driven and physics-based models. This paper aims to present the major challenges in both of these approaches by examining a number of published datasets for their suitability for analysis. Data-driven methods require sufficient samples that were run until failure whereas physics-based methods need physics of failure progression

A Similarity-Based Prognostics Approach for Remaining Useful Life Prediction

Physics-based and data-driven models are the two major prognostic approaches in the literature with their own advantages and disadvantages. This paper presents a similarity-based data-driven prognostic methodology and efficiency analysis study on remaining useful life estimation results. A similarity-based prognostic model is modified to employ the most similar training samples for RUL estimations on each time instance. The presented model is tested on; Virkler’s fatigue crack growth dataset, a drilling process degradation dataset, and a sliding chair degradation of a turnout system dataset. Prediction performances are compared utilizing an evaluation metric. Efficiency analysis of optimization results show that the modified similarity-based model performs better than the original definition

Prognostics with autoregressive moving average for railway turnouts

Turnout systems are one of the most critical systems on railway infrastructure. Diagnostics and prognostics on turnout system have ability to increase the reliability & availability and reduce the downtime of the railway infrastructure. Even though diagnostics on railway turnout systems have been reported in the literature, reported studies on prognostics in railway turnout system is very sparse. This paper presents autoregressive moving average model based prognostics on railway turnouts. The model is applied to data collected from real turnout systems. The failure progression is obtained manually using the exponential degradation model. Remaining Useful Life of ten turnout systems have been reported and results are very promising

Shape-based defect classification for Non Destructive Testing

The aim of this work is to classify the aerospace structure defects detected by eddy current non-destructive testing. The proposed method is based on the assumption that the defect is bound to the reaction of the probe coil impedance during the test. Impedance plane analysis is used to extract a feature vector from the shape of the coil impedance in the complex plane, through the use of some geometric parameters. Shape recognition is tested with three different machine-learning based classifiers: decision trees, neural networks and Naive Bayes. The performance of the proposed detection system are measured in terms of accuracy, sensitivity, specificity, precision and Matthews correlation coefficient. Several experiments are performed on dataset of eddy current signal samples for aircraft structures. The obtained results demonstrate the usefulness of our approach and the competiveness against existing descriptors.Comment: 5 pages, IEEE International Worksho

Production trend identification and forecast for shop-floor business intelligence

The paper introduces a methodology to define production trend classes and also the results to serve with trend prognosis in a given manufacturing situation. The prognosis is valid for one, selected production measure (e.g. a quality dimension of one product, like diameters, angles, surface roughness, pressure, basis position, etc.) but the applied model takes into account the past values of many other, related production data collected typically on the shop-floor, too. Consequently, it is useful in batch or (customized) mass production environments. The proposed solution is applicable to realize production control inside the tolerance limits to proactively avoid the production process going outside from the given upper and lower tolerance limits. The solution was developed and validated on real data collected on the shop-floor; the paper also summarizes the validated application results of the proposed methodology. © 2016, IMEKO-International Measurement Federation Secretariat. All rights reserved

Sensors Data Analysis in Supervisory Control and Data Acquisition (SCADA) Systems to Foresee Failures with an Undetermined Origin

This paper presents the design and implementation of a supervisory control and data acquisition (SCADA) system for automatic fault detection. The proposed system offers advantages in three areas: the prognostic capacity for preventive and predictive maintenance, improvement in the quality of the machined product and a reduction in breakdown times. The complementary technologies, the Industrial Internet of Things (IIoT) and various machine learning (ML) techniques, are employed with SCADA systems to obtain the objectives. The analysis of different data sources and the replacement of specific digital sensors with analog sensors improve the prognostic capacity for the detection of faults with an undetermined origin. Also presented is an anomaly detection algorithm to foresee failures and to recognize their occurrence even when they do not register as alarms or events. The improvement in machine availability after the implementation of the novel system guarantees the accomplishment of the proposed objectives.This work was supported partially by the Basque Government through project IT1207-19, and by the MCIU/MINECO through RTI2018-094902-B-C21/RTI2018-094902-B-C22 (MCIU/AEI/FEDER, UE). The authors would like to thank Intenance Company for its collaboration and help